2004 SUBARU FORESTER Electrical System Problems

WHILE RUNNING THE BLOWER MOTOR ON HIGH, THE CABIN BEGAN TO FILL WITH TOXIC SMOKE. THE BLOWER'S HOT WIRE CONNECTION HAD OVERHEATED, CHARRED/MELTED THE PLASTIC HOUSING AROUND THE TERMINAL, CHARRED/MELTED THE WIRES INSULATION AT THIS CONNECTION, AND MELTED THE COPPER UNTIL IT FELL LOOSE. THE BLOWER RESIDES EXPOSED UNDER THE GLOVE COMPARTMENT. NO EASILY COMBUSTIBLE MATERIALS WERE LOCATED UNDERNEATH THE BLOWER AT THAT TIME. *TR

IN VERY COLD WEATHER (LESS THAN 10 F) THE RUBBER GAS LINES LEAK VERY SIGNIFICANT AMOUNTS OF GAS ONTO THE ENGINE AND VERYNEAR THE HOT TURBOCHARGER. ANOTHER SUBARU JUST CAUGHT FIRE IN THE O'NEILL TUNNEL. HTTP://BOSTON.CBSLOCAL.COM/2014/01/27/CAR-FIRE-CAUSES-BACKUP-IN-ONEILL-TUNNEL/ *TR

THE AIR BAG SYSTEM WILL NOT FUNCTION IN THE EVENT OF A COLLISION DUE TO AN ELECTRICAL CONNECTOR MALFUNCTION. THE CONNECTOR IS LOCATED UNDER THE DRIVER'S SEAT AND IS CONSTANTLY STRESSED BY SEAT MOVEMENT OR CONTACT BY THE DRIVER'S FEET. AS A RESULT, THE AIR BAG WARNING LIGHT IS CHRONICALLY BUT INTERMITTENTLY ON. THIS HAS BEEN A PROBLEM SINCE FIRST IDENTIFIED WHEN THIS VEHICLE WAS APPROXIMATELY 1 YEAR OLD. THE REPAIR OF THE CONNECTOR WAS EVENTUALLY INEFFECTIVE. WHEN THE AIR BAG WARNING LIGHT IS ON THE AIR BAGS ARE INACTIVE AND WILL NOT DEPLOY IN THE EVENT OF A COLLISION. *TR